Ballistic Composite with Matrix Concentration Gradient
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Solution Overview
Problem
The manufacturing of ballistic resistant articles with non-uniformly distributed matrix material faces challenges due to difficulties in consolidating layers with resin-rich and resin-poor areas, requiring additional process steps and precise temperature control for thermoplastic polymer application, which complicates the manufacturing process without ensuring optimal ballistic resistance.
Innovation Solution
A ballistic resistant article comprising consolidated composites with layers A and B, where the matrix material is distributed in a concentration gradient, starting with a maximum value on one surface and decreasing to a minimum on the opposite surface, without the need for additional thermoplastic polymers, using a mixture of 75-95 wt.% polychloroprene and 5-25 wt.% random copolymer of vinyl chloride and acrylic ester, and bonded either by rich-to-poor or poor-to-rich surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If thermoplastic polymer is applied on the outer surface of the composite, then abrasive protection is improved, but manufacturing complexity increases and precise temperature control is required
Solution Approach 1:
The patent extracts the thermoplastic polymer from the composite structure by removing it during processing. The polymer is initially present to facilitate manufacturing but is subsequently removed to leave a clean composite surface without requiring additional protective layers, thereby simplifying the manufacturing process while maintaining protective properties.
Solution Approach 2:
The thermoplastic polymer is applied preliminarily during the manufacturing process to enable easy consolidation of layers, then removed afterward. This preliminary action facilitates the bonding process without compromising the final product quality, eliminating the need for separate protective coating steps.
2Object-affected harmful factors
If thermoplastic polymer film adhesion is increased, then surface protection is improved, but ballistic performance deteriorates
Solution Approach 1:
The thermoplastic polymer is completely removed from the final composite structure through extraction during processing. This eliminates the trade-off between adhesion strength and ballistic performance, as no polymer film remains to potentially compromise ballistic properties while still having served its manufacturing purpose.
3Ease of manufacture
If resin-rich areas are present in the composite, then consolidation difficulty is increased, but manufacturing simplicity is maintained
Solution Approach 1:
The thermoplastic polymer is applied preliminarily to create resin-rich areas that facilitate easy consolidation during manufacturing. These resin-rich regions act as flux during bonding, reducing consolidation difficulty. The polymer is then removed afterward, leaving a clean composite without requiring complex consolidation processes.
Solution Approach 2:
The thermoplastic polymer acts as an intermediary substance during consolidation, mediating the bonding process between fiber layers. It temporarily modifies the resin distribution to enable easy consolidation, then is removed to leave the desired final structure, simplifying the overall manufacturing process.
4Object-affected harmful factors
If additional thermoplastic polymer layer is added to the composite, then abrasive protection is improved, but article weight increases
Solution Approach 1:
Rather than adding a permanent protective layer that would increase weight, the patent uses thermoplastic polymer temporarily during manufacturing and then extracts it completely. This approach provides manufacturing benefits without the penalty of increased article weight from additional protective materials.
Data Source
AI summary
A ballistic resistant article and a method of its manufacture are provided. The article comprises at least one consolidated composite, wherein the at least one consolidated composite comprises a layer A and a layer B bonded to one another, each layer A and B exhibits a first surface, a second surface opposite to the first surface, and a cross-section extending from the first surface to the second surface, each layer A and each layer B comprises a network of fibers having a strength of at least 800 mN/tex (1100 MPa) according to ASTM D 7269-07, and the fibers in each layer A and B are impregnated with a matrix material, characterized in that the matrix material is distributed along the cross-section of each layer in the shape of a concentration gradient, wherein the concentration starts with a maximum value on the first surface, so that the first surface is rich in matrix material, decreases along the cross-section and reaches a minimum value on the second surface, so that the second surface is poor in matrix material, and the matrix material comprises a mixture of 75 to 95 wt.% of a polychloroprene, and 5 to 25 wt.% of a random copolymer of vinyl chloride and an acrylic ester based on a weight of the mixture.